VEHICLE SEAT AND VEHICLE

Abstract

 A vehicle seat includes a seat base including a plate member and a cushion member; and an outer cover member than covers the cushion member and is secured co a back surface of the plate member, the seat base includes a rider support and a side wall extending from a perimeter of the rider support. A folded portion of the outer cover member includes an outer region overlapping an outer side surface of the side wall, a tip region overlapping a tip of the side wall, and an inner region overlapping an inner side surface of the side wall. The outer cover member has a textured portion formed in the folded portion. The outer cover member includes an ink layer in at least a part of the folded portion. The ink layer is continuously formed in the outer region, the tip region and the inner region, ana is continuously formed on the convex portion and the concave portion of the textured portion. A portion of the ink layer that is located on the concave portion has a thickness larger than that of a portion of the ink layer that is located on the convex portion.

Description

TECHNICAL FIELD

[0001] The present invention relates to a vehicle seat and a vehicle.

BACKGROUND ART

[0002] In general, a vehicle seat includes a cushion member having an appropriate level of resilience and an outer cover member covering the cushion member. Patent Document 1 discloses a seat for a straddled vehicle. FIG. 25 shows a seat 90 for a straddled vehicle disclosed in Figure 2(A) and Figure 2(B) in Patent Document 1. FIG. 25(a) is a cross-sectional view showing a part of the seat 90, and FIG. 25(b) is a planar view showing a part of the seat 90 as seen from below.

[0003] The seat 90 includes a seat base 91 and an outer cover member 92. The seat base 91 includes a bottom plate 93 and a cushion member 94 located on the bottom plate 93. The outer cover member 92 covers the cushion member 94. The seat base 91 includes a sitting plane 91a corresponding a sitting plane and a side wall 91b extending downward from a perimeter of the sitting plane 91a.

[0004] The outer cover member 92 has a size larger than that of a surface of the seat base 91 such that a covering work is easily done. As shown in the figure, a peripheral portion of the outer cover member 92 is folded back at a tip of the side wall 91b of the seat base 91 and is secured to a back surface of the side wall 91b (back surface of the bottom plate 93) by staples 95 (is stapled).

[0005] The covering work of the outer cover member 92 is performed as follows specifically. First, the sitting plane 91a of the seat base 91 is covered with the outer cover member 92. Next, the peripheral portion of the outer cover member 92 is pulled in a direction in which the side wall 91b extends. Then, in the state where the peripheral portion of the outer cover member 92 is pulled, the outer cover member 92 is folded back at the tip of the side wall 91b. Next, the peripheral portion of the outer cover member 92 overlapping the back surface of the side wall 91 is stapled by use of a tucker or the like. The staples 95 are driven sequentially along a circumferential direction in the state where the outer cover member 92 is pulled. In this step, a small number of staples 95 may be driven at a relatively large interval, so that the outer cover member 92 is temporarily secured.

CITATION LIST

PATENT LITERATURE

[0006] Patent Document 1: Japanese Examined Utility Model Application Publication No. H1-20232

SUMMARY OF INVENTION

TECHNICAL PROBLEM

[0007] The outer cover member 92 needs to be secured while being pulled at an appropriate force such that a portion overlapping the sitting plane 91a and a portion overlapping the side wall 91b are not wrinkled or broken. Since the outer cover member 92 has a size larger than that of the surface of the seat base 91 as described above, there is an extra portion in the peripheral portion of the outer cover member 92. As shown in FIG. 25(b), this extra portion is secured by the staples 95 while being partially folded up or is wrinkled between adjacent staples 95.

[0008] Unless the peripheral portion of the outer cover member 92 is pulled properly (such that there is no variance in the tensile forced to be stapled, the outer cover member 92 may be wrinkled as floating in a portion thereof corresponding to (overlapping) the tip of the side wall 91b. More specifically, wrinkles may be continuously made from the extra portion to the tip of the folded portion of the outer cover member 92.

[0009] In other words, if two different tensile forces act on two continuous areas in the peripheral portion of the outer cover member 92, the wrinkles from the extra portion of the outer cover member 92 are continued to the tip of the folded portion of the outer cover member 92. Such wrinkles are shown in an external appearance of the seat 90 and is visually recognizable, and thus deteriorates the appearance of the seat 90. FIG. 26 shows the seat 90 in the state where the outer cover member 92 is stapled to the seat base 91. As shown in the regions enclosed by the dashed lines in FIG. 26, the tip of the folded portion of the outer cover member 92 may be wrinkled.

[0010] In the meantime, a textured portion including microscopic convex portions and concave portions may be formed in the outer cover member of the vehicle seat for the purpose of providing an effect of preventing slipping or for the purpose of improving the external appearance. The outer cover member having such a textured portion is easily deformed in a pulling direction from the concave portions, and thus is easily stretchable than an outer cover member having a smooth surface (namely, an outer cover member with no textured portion). Therefore, the outer cover member having the textured portion merely needs a relatively small force to be pulled, but is easily stretched in a different amount by a slightly different tensile force, which easily wrinkles the folded portion.

[0011] The present invention made in light of the above-described problem has an object of providing a vehicle seat suppressing a tip of a folded portion of an outer cover member from being wrinkled.

SOLUTION TO PROBLEM

[0012] A vehicle seat in an embodiment according to the present invention includes a seat base including a plate member and a cushion member stacked on a surface of the plate member; and an outer cover member covering the cushion member, the outer cover member being secured to a back surface of the plate member. The seat base includes a rider support and a side wall extending in a thickness direction of the rider support from a perimeter of the rider support; the outer cover member includes a folded portion folded back at a tip of the side wall; the folded portion includes an outer region overlapping an outer side surface of the side wall, a tip region overlapping the tip of the side wall, and an inner region overlapping an inner side surface of the side wall; the outer cover member has a textured portion formed in the folded portion, the textured portion including a convex portion and a concave portion; the outer cover member further includes an ink layer in at least a part of the folded portion, the ink layer being continuously formed in the outer region, the tip region and the inner region, the ink layer being continuously formed on the convex portion and the concave portion of the textured portion; and a portion of the ink layer that is located on the concave portion has a thickness larger than that of a portion of the ink layer that is located on the convex portion.

[0013] In an embodiment, the side wall of the seat base includes a rounded portion curved in a circumferential direction; and the outer cover member includes the ink layer at least in a region corresponding to the rounded portion in the folded portion.

[0014] In an embodiment, the side wall of the seat base includes two areas that are continuous to each other and have different lengths in the thickness direction of the rider support; and the outer cover member includes the ink layer at least in a region corresponding to the two areas in the folded portion, the ink layer being continuously formed in the outer region, the tip region and the inner region.

[0015] In an embodiment, the ink layer contains a resin material; and the outer cover member further includes an outer cover member main body supporting the ink layer, and an intermediate layer provided between the outer cover member main body and the ink layer, the intermediate layer containing a resin material of a same type as the resin material contained in the ink layer.

[0016] In an embodiment, the resin material contained in the ink layer is an acrylic resin; and the intermediate layer contains an acrylic resin.

[0017] In an embodiment, the portion of the ink layer that is located on the concave portion does not exceed a height from a trough of the concave portion to a peak of the convex portion.

[0018] A vehicle in an embodiment according to the present invention includes the vehicle seat having any of the above-described structures.

[0019] Hereinafter, functions and effects of an embodiment according to the present invention will be described.

[0020] In the vehicle seat in an embodiment according to the present invention, the ink layer is continuously formed in the outer region, the tip region and the inner region in at least a part of the folded portion of the outer cover member. Therefore, as compared with a case where the ink layer is not formed, the rigidity of the folded portion (hereinafter, referred to as an "outer cover rigidity") is higher, and thus the following effects are provided.

[0021] First, the ink layer formed in the tip region increases the outer cover rigidity of the tip region. Therefore, the tip region of the outer cover member is not easily deformed (floated). The ink layer continuously formed in the inner region and the tip region increases the outer cover rigidity of the inner region. Therefore, wrinkles in an extra portion of the inner region do not easily extend long. Namely, the wrinkles in the extra portion of the inner region are suppressed from being continued to the tip region. In addition, the ink layer is continuously formed in the outer region and the tip region. Therefore, the outer region has the outer cover rigidity thereof increased and thus plays a role of restricting the deformation (floating) of the tip region. Thus, the wrinkles continuous from the extra portion of the inner region to the tip region are more difficult to be formed. For the above-described reasons, in the vehicle seat according to the present invention, even if different tensile forces act on two continuous areas of a peripheral portion of the outer cover member, wrinkles are not easily formed in the tip region.

[0022] In the case where the outer cover member has the textured portion, the folded portion is easily wrinkled. In the vehicle seat according to the present invention, the ink layer is continuously formed on the convex portion and the concave portion of the textured portion. Therefore, a portion of the ink layer located on the concave portion (continuous from a portion of the ink layer located on the convex portion) plays a role of limiting the convex portion (restricting the movement of the convex portion) . Therefore, although the outer cover member has the textured portion, the tip region is difficult to be wrinkled. In addition, the thickness of the portion of the ink layer located on the concave portion is larger than the thickness of the portion of the ink layer located on the convex portion. Therefore, the action of limiting the concave portion is made stronger, and thus the Lip region is more difficult to be wrinkled.

[0023] In the case where the side wall of the seat base includes a rounded portion curved in a circumferential direction (i.e. , having a larger radius of curvature than the rest of the circumference), the extra portion is made large in a region of the outer cover member corresponding to the rounded portion. Therefore, during a work of securing the outer cover member to the plate member (performed while the outer cover member is pulled), it is made more difficult to deal with the extra portion in the region of the outer cover member corresponding to the rounded portion. Thus, it is preferred that the ink layer is formed in at least a region, corresponding to the rounded portion, of the folded portion of the outer cover member.

[0024] In the case where the side wall of the seat base includes two areas that are continuous to each other and have different lengths in the thickness direction of the rider support, portions of the outer cover member corresponding to such areas have extra portions having different lengths in the thickness direction of the rider support. Therefore, wrinkles are easily formed in the extra portions. For this reason, it is preferred that the ink layer is formed in at least portions, corresponding to the areas, of the folded portion of the outer cover member.

[0025] The outer cover member may further include an intermediate layer provided between the outer cover member main body and the ink layer. In the case where the intermediate layer contains a resin material of the same type as the resin material contained in the ink layer, the resin material in the intermediate layer and the resin material in the ink layer have a high level of affinity to each other. Therefore, the adhesion of the ink layer is increased. Such a high level of affinity also provides an effect of improving the ability of the ink layer of being colored.

[0026] A preferable resin material contained in the ink layer is, for example, an acrylic resin. The acrylic resin has a high transparency and a high climate resistance. In the case where the ink layer contains an acrylic resin, the intermediate layer preferably contains a resin of the same type, namely, an acrylic resin.

[0027] If the thickness of the portion of the ink layer located on the concave portion exceeds the height from the trough of the concave portion to the peak of the convex portion, the concave portion is completely filled with the ink layer. In this case, the touch of the textured portion (convex and concave portions) is changed. For this reason, it is preferred that the thickness of the portion of the ink layer located on the concave portion does not exceed the height from the trough of the concave portion to the peak of the convex portion.

ADVANTAGEOUS EFFECTS OF INVENTION

[0028] An embodiment of the present invention provides a vehicle seat suppressing a tip of a folded portion of an outer cover member from being wrinkled.

BRIEF DESCRIPTION OF DRAWINGS

[0029] 

FIG. 1 is a side view schematically showing a straddled vehicle (motorcycle) 1 in an embodiment according to the present invention.

FIG. 2 is an isometric view schematically showing a seat 20 included in the motorcycle 1.

FIG. 3 is a side view schematically showing the seat 20.

FIG. 4 is a cross-sectional view taken along line 4A-4A' in FIG. 3, schematically showing the seat 20.

FIG. 5 is a cross-sectional view schematically showing a side wall 34 of a seat base 30 and the vicinity thereof.

FIG. 6 schematically shows a cross-sectional structure of a folded portion 41 (outer region 41a, tip region 41b and inner region 41c) of an outer cover member 40.

FIG. 7 is a planar view of a rear portion of the seat base 30 of the seat 20 as seen from below.

FIG. 8 is a side view showing a part of the seat base 30.

FIG. 9 is a cross-sectional view schematically showing an ink layer 50' formed by a screen printing method.

FIG. 10(a) and FIG. 10(b) are each an optical micrograph showing an outer cover member (including no ink layer) having a textured portion of pattern A.

FIG. 11(a) and FIG. 11(b) are each an optical micrograph showing an outer cover member (including no ink layer) having a textured portion of pattern B.

FIG. 12(a) and FIG. 12(b) are each an optical micrograph showing an outer cover member having a textured portion of pattern A and including an ink layer formed by an inkjet method.

FIG. 13(a) and FIG. 13(b) are each an optical micrograph showing an outer cover member having a textured portion of pattern B and including an ink layer formed by an inkjet method.

FIG. 14(a) and FIG. 14(b) are each an optical micrograph showing an outer cover member having a textured portion of pattern A and including an ink layer formed by the screen printing method.

FIG. 15(a) and FIG. 15(b) are each an optical micrograph showing an outer cover member having a textured portion of pattern B and including an ink layer formed by the screen printing method.

FIG. 16(a), FIG. 16(b) and FIG. 16(c) are respectively graphs showing roughness curves of outer cover members having a textured portion of patter A, in the case where no ink layer is formed, in the case where an ink layer is formed by the inkjet method, and in the case where an ink layer is formed by the screen printing method.

FIG. 17(a), FIG. 17(b) and FIG. 17(c) are respectively graphs showing roughness curves of outer cover members having a textured portion of patter B, in the case where no ink layer is formed, in the case where an ink layer is formed by the inkjet method, and in the case where an ink layer is formed by the screen printing method.

FIG. 18(a), FIG. 18(b) and FIG. 18(c) are each a schematic view showing a cross-sectional structure in the case where an ink layer is formed by the inkjet method on an outer cover member having a textured portion of pattern A.

FIG. 19(a), FIG. 19(b) and FIG. 19(c) are each a schematic view showing a cross-sectional structure in the case where an ink layer is formed by the inkjet method on an outer cover member having a textured portion of pattern B.

FIG. 20(a), FIG. 20(b) and FIG. 20(c) are each a schematic view showing a cross-sectional structure in the case where an ink layer is formed by the screen printing method on an outer cover member having a textured portion of pattern A.

FIG. 21(a), FIG. 21(b) and FIG. 21(c) are each a schematic view showing a cross-sectional structure in the case where an ink layer is formed by the screen printing method on an outer cover member having a textured portion of pattern B.

FIG. 22(a) shows an ink layer 50 formed by the inkjet method, and FIG. 22(b) shows an ink layer 50' formed by the screen printing method.

FIG. 23 is a cross-sectional view schematically showing the side wall 34 of the seat base 30 and the vicinity thereof.

FIG. 24 is a cross-sectional view taken along line 4A-4A' in FIG. 3, schematically showing the seat 20.

FIG. 25(a) and FIG. 25(b) are respectively a cross-sectional view and a planar view showing a part of a straddled vehicle seat 90 disclosed in Patent Document 1.

FIG. 26 shows the seat 90 in the state where an outer cover member 92 is secured on a seat base 91 by stapling.

DESCRIPTION OF EMBODIMENTS

[0030] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to any of the following embodiments.

[0031] FIG. 1 show a straddled vehicle 1 in this embodiment. FIG. 1 is a side view schematically showing the straddled vehicle 1. As shown in FIG. 1, the straddled vehicle 1 is an on-load type motorcycle. In the following description and the drawings, the terms "front", "rear", "left", "right", "up" and "down" respectively refer to front, rear, left, right, up and down as seen from a rider of the motorcycle.

[0032] As shown in FIG. 1, the motorcycle 1 includes a vehicle frame 2. The vehicle frame 2 includes a head pipe 3, a main frame 4, and a seat rail 5. The main frame 4 extends obliquely rearward and downward from the head pipe 3. The seat rail 5 extends obliquely rearward and slightly upward from the main frame 4. A seat 20 is attached on the seat rail 5. The seat 20 includes a rider seat 20A on which the rider may sit and a tandem seat 20B on which a passenger may sit.

[0033] A steering shaft (not shown) is inserted through the head pipe 3. At a top end and a bottom end of the steering shaft, brackets (an upper bracket and an under bracket) 3a and 3b are respectively coupled. A pair of extendable front wheel support members 7 are coupled with the brackets 3a and 3b. At bottom ends of the front wheel support members 7, a front wheel 8 is rotatably attached.

[0034] An engine 9 is suspended to the main frame 4. At a rear end of the main frame 4, a rear arm 11 is attached swingably as being centered around a pivot shaft 10. At a rear end of the rear arm 11, a rear wheel 12 is rotatably attached.

[0035] Now, with reference to FIG. 2, FIG. 3 and FIG. 4, a structure of the seat (vehicle seat) 20 included in the motorcycle 1 will be described. FIG. 2, FIG. 3 and FIG. 4 are respectively an isometric view, a side view and a cross-sectional view schematically showing the seat 20. FIG. 4 shows a cross-section taken along line 4A-4A' in FIG. 3.

[0036] As shown in FIG. 2, FIG. 3 and FIG. 4, the seat 20 includes a seat base 30 and an outer cover member 40. As shown in FIG. 4, the seat base 30 includes a plate member 31 and a cushion member 32. For easier understanding, FIG. 4 shows the cross-sectional structure of the plate member 31 in a simplified manner.

[0037] The plate member (referred to also as a "bottom plate") 31 supports the cushion member 32. The plate member 31 forms a bottom portion of the seat 20, and has a role of providing a certain level of strength to the entirety of the seat 20. Therefore, the plate member 31 is preferably formed of a relatively highly rigid material. The material of the plate member 31 may be, specifically, a resin material such as polypropylene or the like. The plate member 31 includes a stay 31a and a mount 31b securing the seat 20 to the seat rail 5.

[0038] The cushion member 32 is stacked on a surface 31c of the plate member 31. The cushion member 32 is preferably formed of a material that keeps having an appropriate level of resilience for a long time in order to keep providing a high level of comfort of riding. A preferable material of the cushion member 32 may be, for example, foamed polyurethane (urethane foam), but is not limited to this.

[0039] The outer cover member 40 covers the cushion member 32. The outer cover member 40 is stacked on a surface 32a of the cushion member 32. The outer cover member 40 is secured to a back surface 31d of the plate member 31. The outer cover member 40 may be secured to the plate member 31 by, for example, stapling. The outer cover member 40 (more precisely, an outer cover member main body 40a described below) includes, for example, a base layer (lining; formed of, for example, wooly nylon) and a PVC (polyvinylchloride) layer (outer layer) covering a surface of the base layer, but is not limited to having such a structure, needless to say. For example, the outer cover member main body 40a may be formed of, for example, synthetic leather, artificial leather, natural leather or the like.

[0040] As shown in FIG. 4, the seat base 30 includes a rider support 33 supporting at least a part of the body of the rider. In this example, the rider support 33 is a sitting plane that supports the buttocks of the rider. The seat base 30 further includes a side wall 34 extending in a thickness direction TD of the sitting plane 33 (extending downward) from a perimeter of the sitting plane 33.

[0041] The outer cover member 40 includes a folded portion 41 folded inward from an outer side surface of the side wall 34 at a tip of the side wall 34. The folded portion 41 includes an outer region 41a overlapping the outer side surface of the side wall 34, a tip region 41b overlapping the tip of the side wall 34, and an inner region 41c overlapping an inner side surface of the side wall 34. In the state where the seat 20 is secured to the motorcycle 1, the outer region 41a is exposed outside of the seat 20 and is visually recognizable. By contrast, the inner region 41c is not exposed outside of the seat 20 and is not visually recognizable.

[0042] FIG. 5 shows the side wall 34 and the vicinity thereof in enlargement. As shown in FIG. 5, the outer cover member 40 includes an ink layer 50 in the folded portion 41. Hereinafter, a portion 40a of the outer cover member 40 other than the ink layer 50 (portion supporting the ink layer 50) will be referred to as the "outer cover member main body". The ink layer 50 is continuously formed in the outer region 41a, the tip region 41b and the inner region 41c of the folded portion 41. In this example, the ink layer 50 is also formed in a region other than the folded portion 41, and is formed on substantially the entirety of a surface of the outer cover member main body 40a. The ink layer 50 may be colored or transparent (i.e., non-colored). The ink layer 50 may have a stack structure including a colored layer and a transparent layer formed on the colored layer.

[0043] FIG. 6 shows a cross-sectional structure of the folded portion 41 of the outer cover member 40. A textured portion 42 is formed in the folded portion 41 of the outer cover member 40 (more specifically, formed at a surface of the folded portion 41). The textured portion 42 includes a plurality of convex portions 42a and a plurality of concave portions 42b. The textured portion 42 may be formed in a portion other than the folded portion 41. In this embodiment, the textured portion 42 is formed in substantially the entirety of the outer cover member 40. The textured portion 42 including the convex portions 42a and the concave portions 42b, which are microscopic, may provide the outer cover member 40 with an effect of preventing slipping or improve the external appearance of the outer cover member 40. There is no specific limitation on the size or the pitch of the convex portions 42a or the concave portions 42b of the textured portion 42. A height difference between a peak of the convex portions 42a and a trough of the concave portions 42b is, for example, about 10 µm to about 110 µm.

[0044] As shown in FIG. 6, the ink layer 50 is continuously formed on the convex portions 42a and the concave portions 42b of the textured portion 41. Thickness d1 of a portion 50a of the ink layer 50 located on the convex portions 42a (hereinafter, such a portion will be referred to as a "convex region"), and thickness d2 of a portion 50b of the ink layer 50 located on the concave portions 42b (hereinafter, such a portion will be referred to as a "concave region"), are different from each other. Specifically, thickness d2 of the concave region 50b of the ink layer 50 is larger than thickness d1 of the convex region 50a of the ink layer 50. In this specification, the comparison between thickness d1 of the convex region 50a of the ink layer 50 and thickness d2 of the concave region 50b of the ink layer 50 is a comparison between the thickness of the region corresponding to the peak of the convex portions 42a and the thickness of the region corresponding to the trough of the concave portions 42b. Namely, unless otherwise specified, thickness d1 of the convex region 50a is the thickness on the peak of the convex portions 42a, and thickness d2 of the concave region 50b is the thickness on the trough of the concave portions 42b. The "peak" is a portion of the convex portions 42a that protrudes most. The "trough" is a portion of the concave portions 42b that is recessed most.

[0045] Thickness d1 of the convex region 50a of the ink layer 50 is, for example, 5 µm to 20 µm. Thickness d2 of the concave region 50b of the ink layer 50 is, for example, 20 µm to 50 µm. Needless to say, the thicknesses of the ink layer 50 are not limited to the above.

[0046] As described above, in the seat (vehicle seat) 20 in this embodiment, the ink layer 50 is continuously formed in the outer region 41a, the tip region 41b and the inner region 41c of the folded portion 41 of the outer cover member 40. Therefore, as compared with a case where the ink layer 50 is not formed, the rigidity of the folded portion 41 (rigidity of a stack structure including the outer cover member main body 40a and the ink layer 50; hereinafter, referred to as an "outer cover rigidity") is higher, and thus the following effects are provided.

[0047] First, the ink layer 50 formed in the tip region 41b increases the outer cover rigidity of the tip region 41b. Therefore, the tip region 41b of the outer cover member 40 is not easily deformed (floated). The ink layer 50 continuously formed in the inner region 41c and the tip region 41b increases the outer cover rigidity of the inner region 41c. Therefore, wrinkles in an extra portion of the inner region 41c do not easily extend long. Namely, the wrinkles in the extra portion of the inner region 41c are suppressed from being continued to the tip region 41b. In addition, the ink layer 50 is continuously formed in the outer region 41a and the tip region 41b. Therefore, the outer region 41a has the outer cover rigidity thereof increased and thus plays a role of restricting the deformation (floating) of the tip region 41b. Thus, the wrinkles continuous from the extra portion of the inner region 41c to the tip region 41b are more difficult to be formed. For the above-described reasons, in the seat 20 in this embodiment, even if different tensile forces act on two continuous areas of a peripheral portion of the outer cover member 40, wrinkles (as shown in FIG. 24) are not easily formed in the tip region 41b.

[0048] As described above, in the case where an outer cover member has a textured portion, a folded portion is easily wrinkled. In the seat 20 in this embodiment, the ink layer 50 is continuously formed on the convex portions 42a and the concave portions 42b of the textured portion 42. Therefore, the concave region 50b (continuous from the convex region 50a) of the ink layer 50 plays a role of limiting the convex portions 42a in a left-right direction in FIG. 6. In other words, the concave region 50b of the ink layer 50 restricts the movement of the convex portions 42a in a pulling direction in which the outer cover member 40 is pulled to be secured to the seat base 30 (in the left-right direction in FIG. 6). Therefore, although the outer cover member 40 has the textured portion 42, the tip region 41b is difficult to be wrinkled. In addition, in this embodiment, thickness d2 of the concave region 50b of the ink layer 50 is larger than thickness d1 of the convex region 50a. Therefore, the action of limiting the concave portions 42b is made stronger, and thus the tip region 41b is more difficult to be wrinkled.

[0049] The ink layer 50 is preferably harder than the outer cover member main body 40a. In the case where the ink layer 50 is harder than the outer cover member main body 40a, the outer cover rigidity of the folded portion 40 is further increased. Thus, the tip region 41b is still more difficult to be wrinkled.

[0050] The ink layer 50 does not need to be formed in substantially the entirety of the outer cover member 40. The ink layer 50 does not need to be formed in a region other than the folded portion 41. The folded portion 41 is present along substantially the entirety of a circumference of the seat 20, whereas the ink layer 50 does not need to be formed in substantially the entirety of the folded portion 41. As long as the ink layer 50 is formed in at least a part of the folded portion 41, a region of the tip region 41b where the ink layer 50 is formed is suppressed from being wrinkled. In other words, it is preferred that the ink layer 50 is formed in a region of the tip region 41b that would be easily wrinkled without the ink layer 50. Hereinafter, a region where it is preferred that the ink layer 50 is formed will be described specifically.

[0051] The side wall 34 of the seat base 30 typically includes a rounded portion that is curved in the circumferential direction. Paying attention to a rear portion of the seat 20 shown in FIG. 2, the side wall 34 includes a rounded portion in the rear portion of the seat 20.

[0052] FIG. 7 shows the rear portion of the seat base 30 of the seat 20 as seen from below (detailed shape of the plate member 31 is omitted) . As shown in FIG. 7, the side wall 34 of the seat base 30 includes three rounded portions 34R in a region corresponding to the rear portion of the seat 20. The rounded portions 34R are curved in the circumferential direction, namely, are curved as seen in a vertical direction. In other words, the rounded portions 34R have a radius of curvature larger than the rest of the circumference of the side wall 34. The extra portion of the outer cover member 40 is made large in each of the rounded portions 34R. Therefore, during a work of securing the outer cover member 40 to the plate member 31 (performed while the outer cover member 40 is pulled), it is made more difficult to deal with the extra portion. Thus, it is preferred that the ink layer 50 is formed in at least regions, corresponding to the rounded portions 34R, of the folded portion 41 of the outer cover member 40.

[0053] The side wall 34 of the seat base 30 may include two areas that are continuous to each other and have different lengths in the thickness direction TD of the sitting plane 33. FIG. 8 shows an example of such areas. FIG. 8 is a side view showing a part of the seat base 30. In FIG. 8, for easier understanding, the plate member 31 and the cushion member 32 are integrally shown, and the side wall 34 is hatched (the sitting plane 33 is not hatched).

[0054] The two areas 34a and 34b shown in FIG. 8 are continuous to each other in a front-rear direction and have different lengths L1 and L2 in the thickness direction TD of the sitting plane 33. In the case where the side wall 34 includes such areas 34a and 34b, portions of the outer cover member 40 corresponding to the areas 34a and 34b have extra portions having different lengths in the thickness direction TD of the sitting plane 33. Therefore, wrinkles are easily formed in the extra portions. For this reason, it is preferred that the ink layer 50 is formed in at least portions, corresponding to the areas 34a and 34b, of the folded portion 41 of the outer cover member 40 (as described above, the ink layer 50 is continuous in the outer region 41a, the tip region 41b and the inner region 41c).

[0055] The ink layer 50 may decorate the outer cover member 40. Namely, the ink layer 50 may exhibit a predetermined color, a predetermined letter, a predetermined pattern, a predetermined image or the like. As described above, in the seat 20 in this embodiment, the ink layer 50 is formed even in the inner region 41c, which is not visually recognizable, of the folded portion 41. In the case where the ink layer 50 is formed even in a region that is not visually recognizable, the effect of suppressing generation of wrinkles is provided as described above.

[0056] If thickness d2 of the concave region 50b of the ink layer 50 exceeds the height from the trough of the concave portions 42b to the peak of the convex portions 42a, the concave portions 42b are completely filled with the ink layer 50. In this case, the touch of the textured portion (convex and concave portions) 42 is changed. For this reason, it is preferred that thickness d2 of the concave region 50b of the ink layer 50 does not exceed the height from the trough of the concave portions 42b to the peak of the convex portions 42a.

[0057] The ink layer 50 is formed by a printing method. A preferably usable printing method may be, specifically, an inkjet method. A screen printing method is also a well known printing method. Studies made by the inventors of the present application have shown that with the screen printing method, it is difficult to form the ink layer 50 continuously on the microscopic convex portions 42a and concave portions 42b of the textured portion 42 as described above.

[0058] FIG. 9 schematically shows an ink layer 50' formed by the screen printing method. In the case where the screen printing method is used, as shown in FIG. 9, the ink layer 50' is formed on the convex portions 42a but is not formed on the concave portions 42b. A conceivable reason is the following. With the screen printing method, a relatively highly viscous ink material is extruded (rubbed) through holes of a screen by use of a squeegee. Therefore, the ink material is not easily attached to the concave portions 42b, which are at a lower position than the convex portions 42a.

[0059] By contrast, with the inkjet method, the ink material is injected from a nozzle of an inkjet printer as microscopic ink drops. Therefore, the ink material is attached to the concave portions 42b as well as the convex portions 42a. Thus, the ink layer 50 is continuously formed on the microscopic convex portions 42a and the microscopic concave portions 42b of the textured portion 42 in a preferred manner. In the case where the inkjet method is used, the viscosity or the like of the ink material may be appropriately adjusted (e.g., the ink material may be adjusted to have a low viscosity than that of the ink material used for the screen printing method), so that the ink material attached to the convex portions 42a partially move to the concave portions 42b by its own weight. Therefore, thickness d2 of the portion of the ink layer 50 on the concave portions 42b (thickness d2 of the concave region) is made larger than thickness d1 of the portion of the ink layer 50 on the convex portions 42a (thickness d1 of the convex region).

[0060] In the case where the inkjet method is used, examples of the usable ink material (material used to form the ink layer 50) include solvent-based ink, UV-based ink, and solvent-UV-based ink.

[0061] The solvent-based ink contains a pigment, a resin acting as a binder (e.g., thermoplastic resin), and an organic solvent. In the case where the solvent-based ink is used, the solvent-based ink is attached onto the outer cover member 40 and is heated to evaporate the organic solvent (is thermally dried) to form the ink layer 50. The ink layer 50 formed by use of the solvent-based ink has a high climate resistance.

[0062] The UV-based ink contains a pigment, a photopolymerizable monomer and/or oligomer as a precursor of a resin acting as a binder, and a photoinitiator. In the case where the UV-based ink is used, the UV-based ink is attached onto the outer cover member 40 and is irradiated with ultraviolet to form the ink layer 50. The ink layer 50 formed by use of the UV-based ink has a high rub fastness.

[0063] The solvent-UV-based ink contains both of the components of the solvent-based ink and the components of the UV-based ink. The solvent-UV-based ink, for example, dilutes a polymer compound with a solvent to provide viscosity and also rub fastness and climate resistance. In the case where the solvent-UV-based ink is used, the solvent-UV-based ink is attached onto the outer cover member 40, and is irradiated with ultraviolet and thermally dried to form the ink layer 50. The ink layer 50 formed by use of the solvent-UV-based ink has both of a high climate resistance and a high rub fastness.

[0064] Whichever ink may be used, the resultant ink layer 50 contains a resin material. A preferable resin material contained in the ink layer is, for example, an acrylic resin. The acrylic resin has a high transparency and a high climate resistance. Whichever ink may be used, the pigment, among the above-described components, may be removed to make the ink transparent.

[0065] The textured portion 42 may be formed in the outer cover member 40 by any of various known texturing methods.

[0066] Now, an ink layer was formed by the inkjet method on an outer cover member having a textured portion, and separately, an ink layer was formed by the screen printing method on an outer cover member having a textured portion. In each case, an external appearance of the outer cover member including the ink layer was observed. The results will be described.

[0067] Outer cover members having textured portions of two patterns shown in FIG. 10 and FIG. 11 were prepared. FIG. 10 and FIG. 11 are each an optical micrograph of such an outer cover member (the ink layer is not formed) . As seen from the scale bars in the figures, FIG. 10(b) and FIG. 11(b) are of a higher magnification than FIG. 10(a) and FIG. 11(a).

[0068] The textured portion of the outer cover member shown in FIG. 10(a) and FIG. 10(b) has a satin finish with a relatively small size and a relatively small pitch of the convex portions and the concave portions (hereinafter, such a pattern will be referred to as a "pattern A") . The textured portion of the outer cover member shown in FIG. 11(a) and FIG. 11(b) has a larger size and a larger pitch of the convex portions and the concave portions than those of pattern A (hereinafter, such a pattern will be referred to as a "pattern B").

[0069] FIG. 12 and FIG. 13 show optical micrographs of the outer cover members each including an ink layer formed by the inkjet method. It is seen from FIG. 12(a), FIG. 12(b), FIG. 13(a) and FIG. 13(b) that even after the ink layer is formed, the external appearance of each outer cover member sufficiently reflects the convex and concave shape of the textured portion below the ink layer. Namely, it is seen that the textured portion is not completely filled with the ink layer.

[0070] FIG. 14 and FIG. 15 show optical micrographs of the outer cover members each including an ink layer formed by the screen printing method. It is seen from FIG. 14(a), FIG. 14(b), FIG. 15(a) and FIG. 15(b) that in this case also, the external appearance of each outer cover member reflects the convex and concave shape of the textured portion. However, as seen from a comparison of FIG. 13(a) and FIG. 13(b) against FIG. 15(a) and FIG. 15(b), in the case where the screen printing method is used, the contrast in the micrograph is more conspicuous than in the case where the inkjet method is used. This is caused because the ink layer is formed only on the convex portions of the textured portion but is not formed on the concave portions.

[0071] Now, on each of an outer cover member including no ink layer, an outer cover member including an ink layer formed by the inkjet method, and an outer cover member including an ink layer formed by the screen printing method, the convex and concave shape was measured by a surface roughness meter. The results will be described.

[0072] FIG. 16(a), FIG. 16(b) and FIG. 16(c) respectively show roughness curves of an outer cover member including no ink layer, an outer cover member including an ink layer formed by the inkjet method, and an outer cover member including an ink layer formed by the screen printing method. All the outer cover members have the textured portion of pattern A. FIG. 16(a), FIG. 16(b) and FIG. 16(c) also each show the maximum height (the largest height difference between the peak and the trough) of the roughness curve. This is applicable to FIG. 17 described below. The "roughness" refers to the height of a waviness of the convex and concave portions of the outer cover member.

[0073] From a comparison between FIG. 16(a) and FIG. 16(b), it is seen that the height difference is smaller in the case where the ink layer is formed by the inkjet method than in the case where no ink layer is formed. A reason for this is that in the case where the ink layer is formed by the inkjet method, the thickness of a portion of the ink layer that corresponds to the concave portions of the textured portion is larger than the thickness of a portion of the ink layer that corresponds to the convex portions of the textured portion.

[0074] From a comparison between FIG. 16(a) and FIG. 16(c), it is seen that the height difference is larger in the case where the ink layer is formed by the screen printing method than in the case where no ink layer is formed. A reason for this is that in the case where the ink layer is formed by the screen printing method, the ink layer is formed on the convex portions of the textured portion but is not formed on the concave portions of the textured portion.

[0075] FIG. 17(a), FIG. 17(b) and FIG. 17(c) respectively show roughness curves of an outer cover member including no ink layer, an outer cover member including an ink layer formed by the inkjet method, and an outer cover member including an ink layer formed by the screen printing method. All the outer cover members have the textured portion of pattern B.

[0076] From a comparison between FIG. 17(a), FIG. 17(b) and FIG. 17(c), it is seen that the outer cover members having the textured portion of patter B have the same tendency as that of the outer cover members having the textured portion of pattern A.

[0077] Now, on each of an outer cover member including an ink layer formed by the inkjet method and an outer cover member including an ink layer formed by the screen printing method, the cross-sectional structure was observed. The results will be described.

[0078] FIG. 16(a), FIG. 18(b) and FIG. 18(c) are schematic views showing the cross-sectional structure of the ink layer formed by the inkjet method on the outer cover member having the textured portion of pattern A. FIG. 18(b) and FIG. 18(c) show the cross-sectional structure at a larger scale than that in FIG. 18(a). FIG. 18(b) and FIG. 18(c) show the cross-sectional structure at the same scale. In the example shown in FIG. 18(a), FIG. 18(b) and FIG. 18(c), the ink layer 50 has a stack structure including a color layer 50C and a transparent layer 50T stacked on the color layer 50C. The same is applicable to the example shown in FIG. 19 described below.

[0079] From FIG. 18(a), it is seen that the ink layer is continuously formed on the convex portions and the concave portions of the textured portion. From FIG. 18(b) and FIG. 18(c), it is seen that the portion of the ink layer that is located on the concave portions has a thickness larger than that of the portion of the ink layer that is located on the convex portions.

[0080] FIG. 19(a), FIG. 19(b) and FIG. 19(c) are schematic views showing the cross-sectional structure of the ink layer formed by the inkjet method on the outer cover member having the textured portion of pattern B. FIG. 19(b) and FIG. 19(c) show the cross-sectional structure at a larger scale than that in FIG. 19(a) . FIG. 19(b) and FIG. 19(c) show the cross-sectional structure at the same scale.

[0081] From FIG. 19(a), it is seen that the ink layer is continuously formed on the convex portions and the concave portions of the textured portion. From FIG. 19(b) and FIG. 19(c), it is seen that the portion of the ink layer that is located on the concave portions has a thickness larger than that of the portion of the ink layer that is located on the convex portions.

[0082] FIG. 20(a), FIG. 20(b) and FIG. 20(c) are schematic views showing the cross-sectional structure of the ink layer formed by the screen printing method on the outer cover member having the textured portion of pattern A. FIG. 20(b) and FIG. 20(c) show the cross-sectional structure at a larger scale than that in FIG. 20(a). FIG. 20(b) and FIG. 20(c) show the cross-sectional structure at the same scale. In the example shown in FIG. 20(a), FIG. 20(b) and FIG. 20(c), the ink layer 50' has a stack structure including a color layer 50C' and a transparent layer 50T' stacked on the color layer 50C'. The same is applicable to the example shown in FIG. 21 described below.

[0083] From FIG. 20(a), FIG. 20(b) and FIG. 20(c), it is seen that the ink layer is formed on the convex portions of the textured portion but is not much formed on the concave portions (the ink layer is thin) .

[0084] FIG. 21(a), FIG. 21(b) and FIG. 21(c) are schematic views showing the cross-sectional structure of the ink layer formed by the screen printing method on the outer cover member having the textured portion of pattern B. FIG. 21(b) and FIG. 21(c) show the cross-sectional structure at a larger scale than that in FIG. 21(a). FIG. 21(b) and FIG. 21(c) show the cross-sectional structure at the same scale.

[0085] From FIG. 21(a), FIG. 21(b) and FIG. 21(c), it is seen that the ink layer is formed on the convex portions of the textured portion but is not much formed on the concave portions (the ink layer is thin) .

[0086] It is seen from the above description made with reference to FIG. 12 through FIG. 21, use of the inkjet method allows the ink layer 50 to be preferably formed continuously on the convex portions 42a and the concave portions 42b of the textured portion 42.

[0087] Now, with reference to FIG. 22(a) and FIG. 22(b), a difference in the surface structure between the ink layer formed by the inkjet method and the ink layer formed by the screen printing method, more specifically, a difference in microscopic ruggedness at the surface (hereinafter, referred to as the "microscopic ruggedness" or the "microscopic roughness") between the two ink layers, will be described. FIG. 22(a) shows the ink layer 50 formed by the inkjet method, and FIG. 22(b) shows the ink layer 50' formed by the screen printing method.

[0088] As seen from a comparison between FIG. 22(a) and FIG. 22(b), a microscopic ruggedness u (microscopic roughness) at the surface of the ink layer 50 formed by the inkjet method is smaller than that of the surface of the ink layer 50' formed by the screen printing method. More specifically, in the ink layer 50 formed by the inkjet method, the microscopic ruggedness u of each of the colored layer 50C and the transparent layer 50T is smaller.

[0089] The "microscopic ruggedness" refers to the smoothness of the surface of the ink layer that follows the textured pattern of the outer cover member main body. More specifically, the "microscopic ruggedness" refers to the height of the ink layer from a line obtained as a result of the waviness of the convex and concave portions at the surface of the outer cover member main body being corrected to a straight line (average line of the waviness) in a cross-section of the seat taken along the thickness direction. As the height of the ink layer is lower, the smoothness is lower. Namely, the expression that the "microscopic ruggedness is smaller" indicates that the height, from the surface of the waviness of the ink layer, of the microscopic ruggedness that is convex and concave in a direction normal to the surface is small.

[0090] As described above, the ink layer formed by the inkjet method has a small microscopic ruggedness (microscopic roughness) of the surface thereof. Therefore, cracks starting from the surface are not easily continued, and thus the rigidity and the durability are increased.

[0091] In the above, a structure in which the ink layer 50 is directly formed on the outer cover member main body 40a is described. The seat 20 in this embodiment is not limited to having such a structure. As shown in FIG. 23, the outer cover member 40 may further include an intermediate layer (underlying layer) 51 provided between the outer cover member main body 40a and the ink layer 50. The intermediate layer 51 may be formed of, for example, a resin material. In the case where the intermediate layer 51 contains a resin material of the same type as the resin material contained in the ink layer 50, the resin material in the intermediate layer 51 and the resin material in the ink layer 50 have a high level of affinity to each other. Therefore, the adhesion of the ink layer 50 is increased. Such a high level of affinity also provides an effect of improving the color exhibiting ability of the ink layer 50. For example, in the case where the ink layer 50 contains an acrylic resin, the intermediate layer 51 preferably contains a resin of the same type, namely, an acrylic resin.

[0092] FIG. 4 and the like show the shape of the plate member 31 in a simplified manner. There is no specific limitation on the shape of the plate member 31 as long as the plate member 31 allows the seat base 30 to include the side wall 34. FIG. 24 shows an example of shape of the plate member 31. FIG. 24 is a cross-sectional view schematically showing the seat 20, taken along line 4A-4A' in FIG. 3. In the example shown in FIG. 24, the sitting plane 33 of the plate member 31 includes a plurality of regions having different heights (namely, includes a stepped portion) . As can be seen, the plate member 31 may have any of various shapes in accordance with the structure of the seat rail 5.

[0093] The motorcycle 1 shown in FIG. 1 is of an on-load type. The straddled vehicle in this embodiment may be of a so-called off-road type, a moped type, a scooter type or any other type. The term "straddled vehicle" refers to any vehicle on which a rider rides astride, and is not limited to a two-wheel vehicle. The straddled vehicle may be, for example, a three-wheel vehicle (LMW), the vehicle body of which is inclined to change the advancing direction.

[0094] The present invention is not limited to being applicable to the seat of a straddled vehicle, and may be applicable to a vehicle seat widely. For example, the present invention is usable for a seat of a four-wheel automobile.

[0095] In the above, the rider support 33 is the sitting plane. The rider support does not need to be the sitting plane. In a seat including a backrest or a headrest, the rider support may be a portion that supports the back of the rider or a portion that supports the head of the rider.

INDUSTRIAL APPLICABILITY

[0096] An embodiment according to the present invention provides a vehicle seat that suppresses a tip of a folded portion of an outer cover member from being wrinkled. An embodiment according to the present invention is preferably usable for a seat of any of various types of vehicles.

REFERENCE SIGNS LIST

[0097] 

1 Motorcycle (straddled vehicle)

20 Seat

30 Seat base

31 Plate member

32 Cushion member

33 Rider support (sitting plane)

34 Side wall

40 Outer cover member

40a Outer cover member main body

41 Folded portion

41a Outer region

41b Tip region

41c Inner region

42 Textured portion

42a Convex portion

42b Concave portion

50 Ink layer

50a Convex region of the ink layer (portion located on the convex portions of the textured portion)

50b Concave region of the ink layer (portion located on the concave portions of the textured portion)

51 Intermediate portion

Claims

1. A vehicle seat, comprising:

a seat base including a plate member and a cushion member stacked on a surface of the plate member; and

an outer cover member covering the cushion member, the outer cover member being secured to a rear surface of the plate member;
wherein:

the seat base includes a rider support and a side wall extending in a thickness direction of the rider support from a perimeter of the rider support;

the outer cover member includes a folded portion folded back at a tip of the side wall;

the folded portion includes an outer region overlapping an outer side surface of the side wall, a tip region overlapping the tip of the side wall, and an inner region overlapping an inner side surface of the side wall;

the outer cover member has a textured portion formed in the folded portion, the textured portion including a convex portion and a concave portion;

the outer cover member further includes an ink layer in at least a part of the folded portion, the ink layer being continuously formed in the outer region, the tip region and the inner region, the ink layer being continuously formed on the convex portion and the concave portion of the textured portion; and

a portion of the ink layer that is located on the concave portion has a thickness larger than that of a portion of the ink layer that is located on the convex portion.

2. The vehicle seat according to claim 1, wherein:

the side wall of the seat base includes a rounded portion curved in a circumferential direction; and

the outer cover member includes the ink layer at least in a region corresponding to the rounded portion in the folded portion.

3. The vehicle seat according to claim 1 or 2, wherein:

the side wall of the seat base includes two areas that are continuous to each other and have different lengths in the thickness direction of the rider support; and

the outer cover member includes the ink layer at least in a region corresponding to the two areas in the folded portion, the ink layer being continuously formed in the outer region, the tip region and the inner region.

4. The vehicle seat according to any one of claims 1 through 3, wherein:

the ink layer contains a resin material; and

the outer cover member further includes an outer cover member main body supporting the ink layer, and an intermediate layer provided between the outer cover member main body and the ink layer, the intermediate layer containing a resin material of a same type as the resin material contained in the ink layer.

5. The vehicle seat according to claim 4, wherein:

the resin material contained in the ink layer is an acrylic resin; and

the intermediate layer contains an acrylic resin.

6. The vehicle seat according to any one of claims 1 through 5, wherein the portion of the ink layer that is located on the concave portion does not exceed a height from a trough of the concave portion to a peak of the convex portion.

7. A vehicle, comprising the vehicle seat according to any one of claims 1 through 6.

Drawing